3-D sensorless conversion method and apparatus for pump differential pressure and flow

Apparatus comprising:

• a signal processor or processing module configured at least to:
• receive signaling containing information about calibrated motor speed and power data for one or more pumps in a hydronic pumping system;
• and
• provide corresponding signaling containing information to control the one or more pumps in the hydronic pumping system, by determining system pumping flow rate and pressure based upon 3-dimensional discrete distribution functions of pump differential pressure, system flow rate and motor power with respect to motor speed and at least one equivalent hydronic system characteristic variable of an instant system curve Cv using a 3-dimensional sensorless model or algorithm and the signaling received;
• the signal processor or processing module being configured to determine the system pumping flow rate and pressure using the 3-dimensional sensorless model or algorithm, based at least partly on processing the signaling related to the calibrated motor speed and power data;
• the signal processor or processing module being configured to implement the 3-dimensional sensorless model or algorithm based at least partly on processing signaling related to a power conversion relationship between hydronic, mechanical and electrical parameters from a pump to a motor or drive in the hydronic pumping system;
• and
• the signal processor or processing module being configured to implement the 3-dimensional sensorless model or algorithm based at least partly on processing signaling related to equation no. 1, as follows:
• γ(P,Q,W,n,Cv)=0, (1)
• where γ presents the power conversion relationship between hydronic, mechanical and electrical from pump to motor drive that is a function of pump differential pressure P;
• system flow rate Q;
• motor power W;
• motor speed n;
• and the equivalent system characteristic variable of the instant curve Cv.

A hydronic pumping system comprising:

• one or more pumps arranged in the process pipe;
• and
• a controller having a signal processor or processing module configured at least to:
• receive signaling containing information about calibrated motor speed and power data for the one or more pumps;
• provide controller signaling containing information to control the one or more pumps, by determining system pumping flow rate and pressure based upon 3-dimensional discrete distribution functions of pump differential pressure, system flow rate and motor power with respect to motor speed and at least one equivalent hydronic system characteristic variable of an instant system curve Cv using a 3-dimensional sensorless model or algorithm and the signaling received;
• the signal processor or processing module being configured to implement the 3-dimensional sensorless model or algorithm based at least partly on processing signaling related to equation no. 1, as follows:
• γ(P,Q,W,n,Cv)=0, (1)
• where γ presents the power conversion relationship between hydronic, mechanical and electrical from pump to motor drive that is a function of pump differential pressure P;
• system flow rate Q;
• motor power W;
• motor speed n;
• and the equivalent system characteristic variable of the instant curve Cv.